A hacksaw blade is available in different TPI (teeth per inch) to best cut a specific range of material thicknesses. Hacksaw blades are usually meant to cut metals, but in very specific rare cases they are used to cut wood.
The higher the TPI, the finer the cut will be. The lower the TPI, the coarser the cut is going to be.
The lower the TPI…the larger the gap between teeth…and the longer the tooth. This allows more material removal and clean-out with each saw stroke, thus saving cutting time.
The higher the TPI…the smaller the gap between teeth…and the shorter the tooth. This allows the blade to cut thinner material thicknesses without getting hung up in the material.
| TPI | MATERIAL THICKNESS | |
|---|---|---|
| WOOD AND THICK METAL USE | 14 | 1/8″ – 1/2″ |
| HEAVY METAL USE | 18 | 1/8″ – 1/2″ |
| MEDIUM METAL USE | 24 | 3/32″ – 5/16″ |
| THIN METAL USE | 32 | less than 1/8″ |
| GLASS, CERAMICS, MARBLE, FIBERGLASS, AND STEEL | Carbide Rod | – |
The values provided on this chart are a general guideline. Blade TPI recommendations can be found on each manufacturer’s product packaging. Read the entirety of the article for more details.
Material thickness – not diameter – relates to blade TPI.
An economical and easy method to measure material thickness is to use a pocket rule.
If you’re looking for the best high-tension hacksaws, check out our recommendations.
Best Hacksaw Blade for Mild Steel: 14-TPI Hacksaw Blade Overview
- A revolutionary new blade design that delivers up to 100% longer blade life versus the prior generation of LENOX hacksaw blades
- Shatter Resistant
- Bi-metal construction allows blades to bend and flex without breaking
Use a 14-TPI blade to cut thick metal (over 1/8″) will speed up cutting compared to an 18-TPI blade.
| MATERIAL | 14-TPI | 18-TPI |
|---|---|---|
| 1/8″ STEEL U-CHANNEL | 27 sec. | 30 sec. |
| 1/2″ REBAR | 24 sec. | 26 sec. |
Note 1: I am not sure why Lenox suggests using a 14-TPI blade for cutting wood. After several thick wood cutting tests (softwood and hardwood), I discovered a 14-TPI hacksaw blade is hopeless at cutting wood; the blade constantly gets hung up in the material. I also tried a Morse 14-TPI blade and had the same ineffectiveness.
I find that a 18-24 TPI blade works best for cutting wood, or switch to a dedicated wood cutting hand saw for better performance.
Note 2: A Lenox 14-TPI blade has a minimum thickness rating of 1/8″, whereas a Morse 14-TPI blade has a minimum thickness rating of 3/16″. We tested both brands of blades to find the truth in these guidelines.
- The Lenox 14-TPI blade effectively cuts 1/8″ thick material, as stated.
- The Morse 14-TPI blade struggled to cut below 3/16″ and is ineffective in cutting 1/8″ thick material.
- Used to cut pipe, tubing solids, wood, plastic or any machinable metal
- Increased heat and wear resistance for long life
- Flexible to prevent shattering during use
- 10 blades per pack
Note 3: Finding 14-TPI blades at local home improvement stores may not be possible, and many of the hacksaw blade brands don’t offer a 14-TPI model. Don’t worry, a 14-TPI blade isn’t needed for homeowner projects. However, a tradesman that cuts heavy metal regularly may want to experiment with a 14-TPI blade compared to using a 18-TPI blade.
Best Hacksaw Blade for PVC Pipes, and Steel Rods: 18-TPI Hacksaw Blade Overview
A 18-TPI blade gives you many of the same cutting abilities as a 14-TPI blade, but with less effort and smoother cutting.
Cut a wide range of wood thicknesses. A hacksaw isn’t the ideal choice for cutting wood, but for random projects where precision cutting isn’t needed, a hacksaw will get the job done, e.g. cutting a tree limb, demoing a small wall or building structure.
A hacksaw is very effective for plumbing projects that use PVC. A 18-TPI blade cuts through PVC tubing, whether trying to cut and remove existing plumbing, or cutting new PVC to length for a plumbing project. E.g. replacing a garbage disposal, sump pump, or an outdoor drainage project. A heavy-duty utility knife works well to deburr the PVC after each cut.
- T2 Technology provides a long hacksaw blade life
- Shatter-resistant, bi-metal construction allows saw blades to bend and flex without breaking
- Saw blades cut through black pipe, Unistrut, copper pipe, hardened steel, threaded rod and rebar
- 18 TPI
- 12" L x 1/2" W
Note: A DeWALT 18-TPI blade has a material thickness rating of 1/4″ – 1/2″. Most other 18-TPI blades have a minimal material thickness rating of 1/8″, which the DeWALT 18-TPI blade cut effectively too. A confusing discrepancy in DeWALT’s 18-TPI nominal material thickness recommendation.
- Model Number: DWHT20558
- Item Package Length: 13.8582677024"
- Item Package Width: 8.0314960548"
- Item Package Height: 0.2362204722"
Best Hacksaw Blade for Cutting Aluminum, Steel, and more: 24-TPI Hacksaw Blade Overview
A 24-TPI comes standard on hacksaws and from our tests offers the most range. The tooth count and size isn’t too small nor too large.
Note 1: Lenox rates their 24-TPI blade to cut 3/32″ thru 5/16″ for hardened materials, but a wider range of softer materials can be cut.
- Cutting PVC with a 24-TPI blade is just as effective as using a 18-TPI blade.
- Cut lumber and wood dowels from 1/16″ and thicker.
- The LENOX hacksaw uses an I-beam construction, allowing the blade to tension up to 50,000 psi
- Rubberized handles allow for confident handling, even in wet and cold environments
- Hacksaw accepts any LENOX reciprocating saw blade to be used as a jab saw
- LENOX hacksaw stores up to 5 extra 12-inch hacksaw blades in the I-beam
- All hacksaw come with one 12-inch, 24 TPI hacksaw blade
Note 2: Use a power or hand miter saw to make highly accurate cuts. I recommend the Nobex Champion 180 miter saw for many reasons, including: quick and precise cuts without the dust of an electric miter saw. Great for indoor projects!
This blade is also best for cutting bolts, screws, and iron rebar.
Best Hacksaw Blade for Fine Cutting and Thin Metal: 32-TPI Hacksaw Blade Overview
A 32-TPI blade is a must when cutting thin metals, hollow sections, and tubing, e.g. electrical conduit and copper pipe.
- A revolutionary new blade design that delivers up to 100% longer blade life versus the prior generation of LENOX hacksaw blades
- Shatter Resistant
- Bi-metal construction allows blades to bend and flex without breaking
Note 1: A 32-TPI blade is rated to cut material up to 1/8″ material, but a 24-TPI blade cuts just as effectively and faster for materials above 3/32″ (roughly).
Note 2: Once in a while a gutter downspout gets damaged and needs replacing. Unfortunately, a hacksaw (even with a 32-TPI blade) isn’t an economic solution to cut a new downspout to length. The ultra thin material causes the teeth to get hung up. For cutting gutter and downspout material use a circular saw with a metal cutting blade.
